Fort Riley, KS

Fort Riley

Refurbished equipment helps save $147,000 per year in energy costs and another $99,000 in reduced maintenance and deferred capital expenses.

a worker coating the coils on an outdoor air handler

Value Delivered

ECM provided restoration services and protective coatings for 110 HVAC units across 57 buildings at the Fort Riley U.S. Army base. In collaboration with our ESCO client, our rejuvenation process helped protect the existing equipment against future corrosion and restored it to near its original efficiency, with a simple payback of 3.38 years. 

After the project was complete, we performed measurement and verification that estimated energy savings of $147,000 per year—34-percent higher than initial projections. We also calculated an additional $99,000 of savings generated by reducing the amount of labor required to pay their third-party maintenance team and by avoiding costs associated with equipment replacement. 

Client Objectives

The client wanted to extend the useful lifespan and improve the performance of deteriorating, air-cooled HVAC systems that were prematurely aged from harsh environmental conditions. 

Solutions

Our seven-step rejuvenation process included removing existing corrosion and debris, addressing fin and coil deterioration, applying our proprietary HVAC Armor coating, and optimizing the refrigerant system by eliminating oil build up and filter blockages.

Step 1: Pre-inspection and Recommendations

  • Review and document equipment condition to identify issues prior to service

Steps 2 and 3: Coil/Fin Service and Deep Clean 

  • Remove housings and casings
  • Clean and straighten fins
  • Deep clean coils from both sides 

Steps 4 and 5: Equipment Prep and Coating 

  • Mask off areas that do not need coating
  • Apply corrosion inhibitor
  • Spray coating on coils from inside and outside

Steps 6 and 7: Refrigerant System Optimization 

  • Recondition internal surfaces, filters, and fluids
  • Replace dryer filters 
  • Level the charge to factory specifications

Client Background

Established in 1853, Fort Riley is a U.S. Army installation located in central Kansas that covers more than 101,733 acres.